Packaging for Flowable Solids

ABSTRACT

A package for large volumes of flowable solids may comprise 2 or more distinct packages of smaller volume. The 2 or more distinct packages may be bound together to minimize changes in center of gravity during handling. The packages may be bound together by an overwrap. The overwrap may have discontinuities. A method of packaging large volumes of flowable solids by temporarily reducing effective headspace to minimize changes in center of gravity during handling.

FIELD OF THE INVENTION

This application relates generally to packaging for flowable solids, such as processed cereal or dry pet foods.

BACKGROUND OF THE INVENTION

Flowable solids, such as processed breakfast cereal or dry pet food, is often packaged in a pliable bag. The bag may be the final packaging for a consumer who purchases the product in a store, or the bag may be further packaged in a box or other outer package. The use of bags, including bags comprising specialized materials or laminates of materials with specialized properties, are generally efficient in protecting dry products from moisture or contamination over the product's shelf-life. An outer package around the bag, such as a cardboard or laminate box, may be used to protect the bag from punctures or tears during shipping and handling, or may be used to provide a more aesthetically pleasing presentation, as the cardboard may be more amenable to uniform printing than the inner bag.

This arrangement works well for packages of relatively small volume or mass. For example, breakfast cereals are typically available in a bag-in-box package in sizes ranging from about 1 ounce to about 70 ounces (approximately 0.06 to 4.4 pounds, or 0.03 to 2 Kg). However, in some instances, it may be desirable to package a flowable solid, such as a food product, in significantly larger and/or heavier packages. For example, dog food is often sold in bags weighing approximately 5 to 40 pounds (2.3 to 18 Kg), or more. At the higher end of this range, over perhaps 30 pounds (13.6 Kg), the bags can become difficult to handle, even for generally healthy shoppers. At 50 pounds (22.7 Kg) even relatively large, strong consumers may have difficulty manipulating the bags. For example, it may be difficult to lift bags from a store shelf or display, which may be nothing more than a shipping pallet stacked with product in some “warehouse” or discount stores, to a shopping cart; or from a shopping cart to a vehicle, such as the trunk of a car; or from a vehicle into a home, which may involve carrying the product up or down stairs. This difficulty may be exacerbated for smaller shoppers, for whom a 50-pound bag may represent a significant portion of the shopper's body weight; for shoppers who have limited strength or mobility; or for shoppers who are accompanied by children or are otherwise distracted or rushed. However, it may be highly inefficient to purchase food in smaller quantities. For example, some very large or very active dogs may consume over 2 pounds of food per day for a single dog, and multi-dog households or institutions, such as animal shelters or boarding facilities, may use correspondingly greater amounts of food, making it impractical to buy food in packages of less than 30 pounds.

There remains a need for a package for relatively large amounts of a flowable solid which is easy to handle, even for shoppers of average or below average size and/or strength.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an exemplary bag comprising a flowable solid.

FIG. 2A is a perspective view of an exemplary particle of a flowable solid.

FIG. 2B is a perspective view of an exemplary particle of a flowable solid.

FIG. 3 is a perspective view of an exemplary package comprising three distinct bags of flowable solid.

FIG. 4 is a perspective view of an exemplary package comprising two distinct bags of flowable solid.

FIGS. 5A-5E illustrate measures associated with the Drape Measurement Method.

FIG. 6 is a chart showing the average activation of different muscle groups while lifting various packages into or out of a shopping cart.

FIG. 7 is a chart showing the average activation of different muscle groups while lifting various packages from a pallet.

FIGS. 8A-D are illustrations of how a bundle package might be handled by an opening.

FIGS. 9A-D are illustrations of how a bundle package might be handled without using an opening.

FIG. 10 is a chart showing the average activation of different muscle groups while handling a bundle package with or without using an opening.

FIGS. 11A-B are perspective views of stacking configurations for palletizing product.

DETAILED DESCRIPTION OF THE INVENTION

As used herein, “flowable solid,” refers to a composition which, although not liquid or gaseous, will tend to flow or stream from a container when poured. This definition is sometimes used in the food industry or other applications involving powder or particulate handling, and should not be confused with the alternative use of the term “flowable solid” to refer to substances, like glass, which are thought of as solids, but will noticeably flow over prolonged periods of time. Glass and similar highly viscous liquids or semi-solids can be “flowable solids” as used herein, however, “flowable solids” as used herein embraces other materials, including compositions that are flowable as an aggregate of particles but are not flowable in the same sense as glass.

As used herein, “headspace” refers to the interior volume of a package which is not occupied by a flowable solid. The headspace may contain predominantly air (e.g., atmospheric gas) or an inert gas, possibly mixed with moisture and/or volatile compounds that evolve from the flowable solid.

In some aspects, this disclosure relates to a package which facilitates the handling of relatively large volumes and/or weights of flowable solids. The package may comprise 2 or more distinct sub-packages bound together. The 2 or more distinct sub-packages may be bound together in a manner which inhibits the movement of the flowable solid within the packages. By inhibiting the movement of the flowable solid, the package may be easier for a single person to move or manipulate the package.

Flowable solids are often packaged in flexible containers, such as bags. Flexible containers may be convenient for one or more of several reasons. A bag, particularly, but not exclusively, a bag containing synthetic polymers, specialized materials, or laminates of materials having specialized properties, may be efficient in protecting the flowable solid from moisture, oxygen, or other potential causes of degradation. In some cases, this protection may be important to preserving the texture, flavor, efficacy, or even safety of the flowable solid. For example, food products exposed to excessive moisture may be more vulnerable to potentially harmful microbial growth during storage.

A pliable bag may also be useful in storing a flowable solid. Because the contents can move relative to the package, and the package itself can change shape somewhat, a flowable solid stored in a pliable bag provides some flexibility in where the bag can be stored. For example, a bag of flowable solids might be stored “upright” or on its side, or might be deformed from its intended shape (e.g., generally rectangular) so as to fit in space available in a vehicle, closet, pantry, garage, secondary container (such as a box, chest, or tub), or other space, where a rigid container of the same nominal dimensions as the pliable bag would not conform to the available space. Further, a pliable bag may be helpful in dispensing the flowable solid from the bag. The bag may be lifted or tilted from one end to empty or partially empty the bag. In some instances, the pliability of the bag may be useful in controlling the amount of product emptied from the bag when it is lifted or tilted. For example, the pliable bag may be deformed to partially segregate a portion of the product inside the bag before the bag is partially emptied. Alternately, a scoop or measure may be inserted into an opening in the bag to remove product from inside the bag.

These advantages in storing or dispensing a flowable solid from a pliable bag require that the flowable solid have some ability to move or shift position within the pliable bag. For example, a pliable bag filled to its volumetric capacity, or a vacuum-packed pliable bag, would not be as efficient in adapting to differently shaped storage spaces, and could not be deformed to segregate a portion of the product inside the bag before it is dispensed, at least not without difficulty. Unfortunately, when the flowable solid can move within the package, the package is more difficult to handle. That is, if the bag allows the product to move when the bag is manipulated, then the flowable solid may move when the bag is picked up. Depending on how the flowable solid moves within the bag, this could significantly change the shape of the bag upon handling and the location of the center of gravity with respect to the handling points in the bag. In some instances, the shape and the center of gravity may change repeatedly as the bag is lifted and/or manipulated. That is, the shopper or handler must adjust to a change in the center of gravity upon initial lifting of the bag, and may have to adjust to on-going shifts in the center of gravity (and/or moment of inertia, among other aspects) as the bag is moved or carried. This requires additional strength, balance, and coordination relative to a package of similar weight with fixed kinetics. Multiple options have been explored for addressing this problem. Smaller packages of flowable solid can be provided. This does not solve the variable center of gravity problem, but it does allow a shopper or handler of more limited strength, balance, or coordination to handle the package. Unfortunately, this may require purchasing several packages instead of one package, which may be inconvenient. For example, instead of handling one bag, the shopper or handler must move several bags. This may also complicate storage, since it may be difficult to neatly and stably stack multiple pliable bags of flowable solids. Another approach is to vacuum pack a large bag, but this does not fully remove the tendency for the bag to fold or change shape upon handling, and vacuum pack can lead to kibble particles being impressed on the plastic laminate from the inside which can create not only an unappealing bumpy look but also the possibility of accidental perforations that would work against the integrity of the package. Another approach is to provide a rigid outer package, such as a reusable tote or sturdy cardboard box. However, unless the tote or cardboard box is filled to its volumetric capacity, the flowable solid can still shift inside, although perhaps less than in a comparably filled, pliable bag. Thus, this could reduce, but does not necessarily eliminate, the difficulty of handling a large volume of flowable solid. Further, a rigid outer package may defeat many of the advantages of using a pliable bag, and, if the outer package is used as an adjunct to, rather than a replacement for, the pliable bag, the rigid outer package may also have an undesirable environmental impact. Even if the rigid outer package is recyclable, as additional packaging it will add weight to the product. This additional weight may be small for any individual package, but significant over many dozens or hundreds of packages, and may, therefore, increase fuel consumption and greenhouse gas emissions when the product is shipped to distributors, retail centers, and the like.

It has been surprisingly found that these disadvantages can be overcome by tightly bundling two or more pliant bags containing flowable solids, and that the tightly bundled bags are preferred over alternative approaches. Although it seems that a rigid outer container would potentially present a more aesthetically pleasing appearance and simplify handling, focus groups indicated that prototype bundle packs as described below are easier to pick up, easier to move, and would be easier to store. In addition, focus groups indicated that the ability to separate the bags in the bundle pack and open them separately, at different times, may present advantages in preserving the freshness of a large volume of product or be perceived as preserving the freshness of a large volume of product, where the product may be used over days or weeks, rather than all at once.

FIG. 1 shows an exemplary bag 10. Bag 10 may be pliable, and may contain a flowable solid 22 and a headspace. Bag 10 may have a closure 32, which may be any suitable closure, such as a portion of bag 10 which is folded over and adhered to itself, a zip-type closure, a press-fit closure, a heat seal, a cold pressure seal, an ultrasonic seal, and the like. The headspace may make up between 5% and 30%, or more, of the volume of the bag. The headspace of the bag may be determined by calculating the volume of the bag from its dimensions, emptying the flowable solid from the bag, and measuring the volume of the flowable solid. The volume of the bag is calculated to include any space within the bag which is or could normally (without packaging failure) be available for the flowable solid to move into. For example, if the bag has gussets which are folded but not secured, the volume of the bag should include the volume available when the gussets are unfolded. The headspace is calculated as the volume of the bag minus the volume of the flowable solid. Because the flowable solid may settle somewhat differently within a measuring vessel each time the flowable solid is poured into a measuring vessel, the volume of the flowable solid should be measured at least 3 times and the average volume measurement used to calculate the headspace.

The “effective headspace” of the bag refers to the volume of headspace that is available or open to the flowable solid; that is, the free space in the bag that is available to allow the flowable solid to move or shift position. Thus, if the bag is folded, creased, compressed, or otherwise arranged such that flowable solid cannot enter what would otherwise be open volume or headspace in the bag, the effective headspace is calculated using only the dimensions of the bag that are free or open to accept flowable solid.

Bag 10 may comprise at least 8 pounds, or at least 10 pounds, or 8 to 50 pounds, or 10 to 50 pounds, or 20 to 50 pounds, or 25 to 50 pounds, of flowable solid 22. The flowable solid may be a fine particulate, having an average particle diameter greater than about 5 micrometers, or may be in “macro” particles, such as pellets or kibble 38 having average particle diameters up to about 40 mm, or any other size, provided that the particles are flowable when tipped or poured.

The average diameter is measured as the diameter 36 of the smallest sphere (represented by circle 34) which would circumscribe the entire particle, as shown in FIGS. 2A and 2B, and calculated from 10 randomly selected particles. The shape of the particles is inconsequential, so long as the particles are flowable when tipped or poured. In some instances, it may be desirable to keep the total weight of the flowable solid in the package to 50 pounds or less, to increase the number of shoppers who should be able to handle the package without assistance, and to decrease the risk of injury which may occur from trying to handle excessive weights. In other instances, it may be acceptable to provide packages comprising up to 100 pounds, or up to 120 pounds, of flowable solid. For example, larger packages may be acceptable in settings where it is expected that two or more people may handle the packages cooperatively, or where mechanical assistance devices may be available for handling the packages.

The materials and construction of bag 10 may be adapted to the composition inside the bag. As an example, a dry pet food kibble may be packaged inside a bag as described in U.S. Application Publication No. 2011/0027418, titled “Animal Food Having Low Water Activity”. Multiple alternative constructions are possible and do not limit the applicability of the package as disclosed. Without limitation, the bag may comprise natural or synthetic fibers or materials, may be waterproof or water resistant, and may be reusable or disposable. The bag may comprise a single layer or multiple layers of material, and any single layer may itself be a single, uniform material or may be a laminate of like or dissimilar materials. The bag may, in addition to comprising the flowable solid, comprise dessicants, humectants, antioxidants, buffers (such as acids, bases, or salts thereof), or other active ingredients, within the bag or on the surface (interior, exterior, or both) of the bag, to help maintain the flowable solid in a desired condition, physically and/or chemically, during production, shipping, handling, storage, and/or use. In one specific embodiment, the bag may be constructed from a plastic laminate having an outer layer of polyethylene terapthalate (PET) and an inner layer of a co-extruded blend of linear low density polyethylene, medium polyethylene, and linear low density polyethylene. In this embodiment, the bag has a Water Vapor Transmission Rate of 6×10⁻⁶ g*ply/d/cm²/mmHg.

Two or more bags, such as 10 a, 10 b, 10 c of flowable solid (not shown), may be bound together by an overwrap 28 to form a package 20. FIGS. 3 and 4 show two or three bags, however, it should be understood that additional bags can be included in package 20, such that package 20 contains three bags, or four bags, or even five bags. The bags 10 a, 10 b, 10 c, if not uniform in all dimensions (e.g., not roughly spherical or cubical) may be laid side-to-side to along their longest axis. Pairing the bags 10 a, 10 b along their longest side may facilitate applying overwrap 28, and may also make package 20 easier to handle, particularly if, as in FIG. 3, one side of bags 10 a, 10 b, 10 c is significantly longer than the other sides. As shown, bags 10 a, 10 b, 10 c are of the same size, however, it is possible to use overwrap 28 to manage two or more bags of different sizes.

Overwrap 28 may be a plastic film, such as that used for pallet wrapping, and may be blown or cast, and of any desired gauge. Overwrap 28 may have stretch or shrink properties to help bundle bags 10 a, 10 b tightly together, to minimize the movement of flowable solid 22 a, 22 b within bags 10 a, 10 b, even when package 20 is moved or moving. Overwrap 28 may comprise paper, paperboard, or fiberboard or other materials, for example, such materials may be incorporated into a shrink or stretch material, as by laminating a label or paperboard structure onto a shrink or stretch material. Overwrap 28 can be transparent, translucent, or opaque, and may be colorless, tinted, or richly colored. Overwrap 28 may be different in different portions of the overwrap. For example, part of overwrap 28 may be transparent, and part may be opaque, or different parts of overwrap 28 may have different colors, tints, printing, and the like. Overwrap 28 may tend to adhere to itself, or may be sealed to itself through any suitable means, including heat sealing, cold pressure sealing, adhesive sealing (including applied glue or the use of adhesive tape), ultrasonic sealing, and the like, at one or more seals. Overwrap 28 may include one or more perforations, peel-away strips, pull tabs, or other easy-open features to help remove overwrap 28 when package 20 arrives at its final destination. Overwrap 28 may be printed or may have labels or other indicia applied to its outer surface to identify the flowable solid 22 inside package 20, or overwrap 28 may be designed to as not to interfere with indicia on bags 10 a, 10 b which include information, such as the identity of flowable solid 22, that may be relevant to a shopper or someone handling package 20. The selection of the overwrap material may be such that it will not substantially adhere to outer material of the individual bags to be bundled, so as to enable easy removal of the overwrapped material upon opening of the package and prevent any damage to the appearance or integrity of the individual bags comprised in the package. Non-limiting examples of material combinations may include a paper substrate inner package combined with a polyolefin or polyethylene shrink film or a plastic (e.g. PET/PE, PET/BPOA/PE, PET/mBOPP/PE, or the like with PET outer layer) film structure with a polyolefin or polyethylene shrink film. An example of non-compatible material could be paper bags with a plastic film label to bundle the products resulting in bag destruction when removing the plastic film label.

In some cases, non-vacuum packed bags, even those with little headspace, may allow the flowable solid to move. The freedom to move may increase the more the shape of the bag deviates from the shape of a sphere, as less-spherical packages require more bag surface area for a given volume. For example, a flat rectangular bag may have nearly twice as much surface area as a spherical bag of the same volume. An overwrap may be used to create a package that is closer to a sphere than the individual bag(s). In some embodiments, the excess surface area of an overwrapped package as compared to the surface area of a sphere of equal volume is less than 50% of the surface area of the sphere, preferably less than 40%, or preferably less than 35%, while also preferably more than 10%, preferably more than 20%, or preferably more than 25%, for improved ergonomics. The excess surface area of an overwrapped package, as compared to the surface area of a sphere of equal volume, may be between 25% and 35%.

Overwrap 28 may compress the bag(s) in the package, stiffening the bundle. This stiffening may reduce changes to the shape of the bundle and changes to the location of its center of gravity upon handling, which would facilitate predictable handling. Stiffness can be measured using the Drape Measurement Method described below. As measured a lower drape measurement is indicative of a more rigid (e.g., stiffer) package. In some embodiments, the package may have a drape measure less than 0.8, preferably less than 0.6, preferably less than 0.4, preferably less than 0.2.

Overwrap 28 may be left open at one or more ends of package 20, as shown in FIGS. 3 and 4. These openings 40 may serve as hand-holds when picking up or manipulating package 20. In some embodiments, excess material may be bunched or rolled at the ends of package 20 to form rudimentary grips. In some embodiments, the ends of package 20 may be augmented with additional material like or unlike overwrap 28, to provide distinct grips. Augmented grips may be cushioned or formed of a “cushiony” material, such as foam, to make grasping and lifting package 20 more comfortable on the handler's hands. Augmented grips may be formed or shaped to accommodate a hand or fingers and thus be more comfortable on the handler's hands. At a minimum, if opening(s) 40 are augmented, the ends may be “padded,” rounded, or otherwise designed to help distribute the force of lifting package 20 over more than the narrow strip of overwrap 28 which might otherwise form the end of package 20. That is, augmented ends may be used to reduce the pressure on the hands of a handler of package 20. Alternately, overwrap 28 may be placed such that openings 40 expose an end of one or more bags within package 20, so that the end of the bag may serve as a grip or handle. For example, a handler of package 20 may slide his or her hands in between two bags within package 20, and lift package 20 by the bag within package 20. If openings 40 are used to handle package 20 of bags of equal size, the length of overwrap 28 may be greater than the length of the bags within package 20, and less than the length plus the height of the bag, to leave a suitable opening 40 for grasping package 20.

Package 20 may comprise one or more stiffening inserts. Such inserts may be, for example, heavy-duty cardboard or other stiff, durable members. The inserts may help to prevent the bag(s) inside package 20 from sagging in between the points where the package is gripped by a shopper or handler. An insert may be particularly, but not exclusively, useful if the bag(s) inside package 20 still have significant effective headspace after folding and/or bundling. If used, an insert may be printed or ornamented to provide useful information, attract attention, or provide an aesthetically pleasing appearance for the package. In some embodiments, no stiffening insert or member is present. In some embodiments, the rigidity of package 20 is increased over the bag(s) inside package 20 only by decreasing the effective headspace of the bag(s), as by folding and/or bundling the bags. In some embodiments, the rigidity of package 20 is increased over the bag(s) inside package 20 by restricting the movement of the headspace location, as by tightly bundling the bag(s) with a compressive overwrap 28. In another embodiment the rigidity of package 20 is increased over the bag(s) inside package 20 by restricting the movement of the headspace location and decreasing the effective headspace of the bag(s), as by folding and/or tightly bundling the bags. In some embodiments, package 20 excludes a pallet or other durable shipping aid, but may be placed, stacked, or stored on a pallet or other durable shipping aid. For example, package 20 may not comprise a pallet or other durable shipping aid within overwrap 28, if present.

When placed in an overwrap, a bundle of individual laid down bags stacked vertically one over the other has a lower bulge to equivalent gusset height ratio than a comparative single individual bag of equivalent designed footprint and weight as the bundle. This may result in improved pallet fit and design options as well as a better package readability and/or recognition for the consumer to see information about the product, such as the name or type of product, or other information on the label. In particular, the use of a bundle pack as described herein may enable the safe vertical stacking of packages on a pallet at heights or in configurations which are not possible with comparable individual bags. These bundle packs may be further secured to the pallet and/or to one another on a pallet, as by shrink wrap, overwrap, bands or belts, as is often done for palletized product. Nonetheless, the bundle pack enables different stacking patterns and stacking heights than comparable individual bags. In an individual bag, where a flowable solid is able to move due to headspace in the package, the individual packages can shift during palletization, leading to uneven heights within a vertical layer of packaging. Further, the flowable solid may move in response to the placement of other individual packages nearby. When there is capacity for movement within the palletized product, the palletized product may become unstable and fall over. This limits the configurations and/or stacking heights which can be safely used with conventional, individual packages of flowable solids.

Conforming the dimensions of the packs, as by using a bundled package as described herein, may also enable stacking the packages while they are vertical. Being able to stack the packages vertically enables different palletizing or stacking patterns. As shown in FIGS. 11A and 11B, reorienting packages 200 of the same size on a pallet 210 can result in the addition of one or more packages 200 to the pallet 210. FIG. 11A shows a stacking configuration which yields 35 packages per pallet. FIG. 11B shows an alternative stacking configuration for packages having the same dimensions as those in FIG. 11A, but the stacking configuration of FIG. 11B yields 36 packages per pallet. When shipping many packages, an increase of even 1 or 2 packages per pallet can contribute to reduced material use (e.g., fewer pallets, and less overwrap or banding material to secure product to the pallet for transportation), reduced shipping costs (more packages per pallet means more packages per truck, train car, boat, or other mode of transportation), and reduced carbon emissions associated with shipping the products.

In an individual bag of substantial weight, which might be stored in relatively low positions in a shopping area, the bulge along the sides of the package may reduce the visibility of label information on the bottom of the bulge. That is, the bulge, possibly in concert with a standing person's line of sight due to the position of the package on a shelf or display, may render some of the label information difficult or impossible to see, or to see clearly. Of course, if a bag is stored in a relatively high position, label information on the top of the bulge may be relatively inaccessible. The equivalent gusset height of a bundle of individual bags stacked vertically is determined as the sum of the individual gusset heights of each of the bags in the bundle. The gusset height, GH, of an individual bag is determined as the actual distance between edge creases in the gusset in a flat position. This should not be confused with the distance between edge creases when the bag is full and bulging. The bulge is determined as the difference between the width of a laid down bag filled with flowable solid, Wf, and the designed bag width as measured between edge creases in a flat position (or empty bag), We, so Bulge=Wf−We.

In some embodiments, a package may comprise an equivalent gusset height above 5 inches, preferably above 7 inches, preferably above 9 inches, or preferably above 11 inches, and/or less than 26 inches, preferably less than 24 inches, preferably less than 22 inches, preferably less than 20 inches. In some embodiments, a package may comprise a bulge to equivalent gusset height less than 0.6, preferably less than 0.4, preferably less than 0.2. In one embodiment a bundled pack comprising three laid down bags stacked vertically one over the other has an equivalent gusset height of 9 inches and a bulge to equivalent gusset height ratio of 0.16. In another embodiment a bundled pack comprising four laid down bags stacked vertically one over the other has an equivalent gusset height of 14 inches and a bulge to equivalent gusset height ratio of 0.18. In another embodiment a bundled pack comprising three laid down bags stacked vertically one over the other has an equivalent gusset height of 15 inches and a bulge to equivalent gusset height ratio of 0.31.

When placed in overwrap 28, the effective headspace in bags 10 a, 10 b may be reduced in order to form a solid, brick-like package that does not experience the shifting center of mass and moment of inertia that bags 10 a, 10 b might. If the bag is gusseted or darted, this may manifest as partially or completely closed gussets or darts 42, as shown in FIG. 3. Alternately, or in addition, there may be creases or folds in the material elsewhere along the bag surface, either in pre-defined or more-or-less random locations as the bags are bound into package 20. That is, the bag structure or the overwrap process or both may be designed to fold or crease the bag in specific locations, or the bag may be allowed to fold or crease without intentional direction (although a uniform and/or mechanized process for preparing a package may make this less than truly random).

In some embodiments, the bags may be folded over so that the material in the bag that would enclose headspace rather than flowable solid is folded back on itself prior to forming package 20, as shown in FIG. 4. If the bags, as a result of printing, other indicia, or structure, have a top and a bottom, the bags may be folded over at the top, at the bottom, or along the sides of the package. If the bags are folded, they may be secured in the folded position by a securement means, such as tape, adhesive (including cohesives), overwrap, mesh, mechanical fit, or combinations thereof. The securement may be frangible. With reference to the securement, frangible means that the securement may be broken or disabled without opening or damaging the bag or its contents. For example, if tape is used to secure the bags, the tape may have a sufficiently low adhesion force to the bags that the tape can be easily removed without stripping the bag of any functional or cosmetic outer layer. That is, the tape and the bag may be mutually selected so that, after removing the tape, the bag will serve any intended barrier function (e.g., as a barrier to moisture, oxygen, pests, children, etc.) and the tape will not disrupt labeling or indicia that might be useful in identifying the contents of the bag, reading instructions for using the contents of the bag, or the like. A frangible securement, in addition to protecting the function of the bag(s) in the package, may be helpful in enabling a shopper or handler to access the benefits of a pliable bag having a headspace, when those benefits would exceed the benefits of having a lower effective headspace. For example, it may be desirable to provide a package with a low effective headspace to make it easier to lift the package into a shopping cart, vehicle, or other conveyance, and desirable to provide a pliable bag with an open headspace that is easier to conform to available storage space, or to use to pour or dispense the contents of the bag once the bag has been moved to its ultimate location.

The securement, such as an overwrap, may cover substantially all of the bag(s). For example, the overwrap may cover 80% or more of the surface area of the bag(s) as stacked. The overwrap may be continuous or discontinuous. For example, if the overwrap is a stretch wrap, tape(s) or strap(s) which is(are) wound around the bag(s) several times, it is not necessary that the overwrap touch or overlap across the entire side surface of the bag(s), so long as the overwrap is sufficient to secure the intended effective headspace of the package. If a mesh is used to secure the package, the mesh structure may overlay 80% or more of the surface area of the bag(s) as stacked (i.e., of the surface area taken along the perimeter of the package, excluding the surface area of facing sides of the bags in a multi-bag package), even if the discontinuities in the mesh mean that a much smaller portion of the surface area of the bags is “covered” or obscured by the mesh. The overwrap may be a single piece or continuous web of material, such as stretch wrap applied from a single roll source, or may be comprised of two or more pieces of material, such as two or more webs of stretch wrap. If the overwrap comprises two or more pieces of material, the pieces may be joined, overlapped, or affixed to one another, in parts or in whole (e.g., some pieces joined to other pieces, but not all pieces joined directly or indirectly, or all pieces joined directly or indirectly, as by joining one piece to another, which is joined to yet another piece, which is joined to yet another piece), or the parts may not be joined, overlapped or affixed to one another.

The securement may secure the bag(s) in a condition with an effective headspace at least 75% less than the headspace of the bag(s) when they are not folded, secured, or bound. In some embodiments, the securement may secure the bag(s) in a condition with an effective headspace at least 95% less than the headspace of the bag(s) when they are not folded, secured, or bound. One, more than one, or all of the bags in a package may be bound in a condition which results in an effective headspace at least 75%, or at least 95%, less than the headspace of the bag when it is not folded, secured, or bound. In some embodiments, a single bag containing a large volume of flowable solid, such as at least 40 pounds, or at least 50 pounds, or at least 55 pounds of flowable solid, is folded and secured to reduce effective headspace. Such a single-bag package may present some benefits of a package comprising two or more bags, such as improved handling, and may not present any drawback in terms of freshness if, for example, the contents of the bag may be used at once, with no leftover material to be stored for later use. The bag or bags, whether packaged individually or in a multi-bag package, may comprise features to help preserve the contents of the bag after the bag is opened, such as a resealable opening (e.g., an opening equipped with adhesives, cohesives, or press-fit/zip-style closures that can be opened, reclosed, and opened again).

The flowable solids in different bags in a package may be the same or different compositions. For example, one flowable solid may be one flavor of dog food, and a second flowable solid may be a different flavor of dog food. As a more specific example, a first flowable solid may be dry dog food kibble flavored with lamb and rice, and a second flowable solid may be dry dog food kibble flavored with chicken and rice. In other embodiments, different flowable solids may be complimentary or adjunct products, such as cat food and cat litter, or dog food and dog treats, or a food product to support nursing mothers and a food product suitable for weaning infants/puppies/kittens, or breakfast cereal and freeze-dried fruits, or combinations of different dehydrated foods, candies, chemicals, or the like.

This disclosure describes flowable solids with most frequent reference to pet foods, such as dry dog food. However, the packages and packaging methods described may be useful with regard to a variety of flowable solids, including human foods, such as breakfast cereals, other processed foods, candies, vegetables, and breads (particularly, but not exclusively, rounds, mini-loaves, rolls, or muffins); household chemicals, such as salt (as for a water softener or de-icing purposes), detergents, and pesticides; agricultural products, such as seeds, mulch, pebbles, processed or pelleted fertilizers (in contrast, unprocessed manure, for example, may clump and resist flowing when dispensed from a bag), pesticides, or fungicides, and other soil additives; or industrial products in solid, particulate form, such as extrusion resins. Although the potential benefits are described largely in relation to an individual shopper or consumer in a shopping center, vehicle, or home, it should be appreciated that similar handling benefits may accrue when products are handled in a workplace or other setting, including stores, farms, loading docks, manufacturing areas, and the like, where individuals may be called upon to manually manipulate relevant volumes of a flowable solid.

Drape Measurement Method

The drape measure is indicative of the ability of a package to retain its shape upon handling, and measures an amount of deformation of the package upon placing it on a test stand. FIGS. 5A-5E illustrate the set-up for performing this method, as described below.

The test stand 100 comprises a horizontal surface 101 located above a floor surface 102 a minimum distance H equivalent to the longest dimension of the package to be measured, and supported in that location by any means that would enable surface 101 to support the weight of the package to be measured. Surface 101 further comprises a straight end edge 103. The stand further comprises a horizontal ceiling surface 104 with ability to move up and down and ability to slightly compress a package placed between surface 101 and ceiling surface 104 with a weight approximately equivalent to that of the package being measured, or within 10% of the weight of the package. A weight 107 can be used to approximate the weight of the package.

Before a package is measured, three orthogonal surfaces are chosen on the package that would naturally correspond to a front, side, and bottom surfaces of the package. The largest of such surfaces is labeled S1, the smallest surface is labeled S3 and the remaining surface is labeled S2. If two surfaces are equal and larger than the third, then those two are labeled S1 and S2, and the third labeled S3. If two surfaces are equal and smaller than the third, then those two surfaces are labeled S2 and S3 and the third labeled S1. If all three surfaces are equal, then any one surface can be S1, another S2 and the last one S3.

The package is placed a first time on surface 101 such that surface S1 is fully supported by surface 101, and oriented such that the longest length of surface S1 is perpendicular to straight end edge 103. Ceiling surface 104 is lowered over the package so that it slightly compresses the package between surface 101 and ceiling surface 104 with a weight approximately equivalent to that of the package being measured, or within 10% of the weight of the package. The distance D (105) between the surface 101 and ceiling surface 104 is recorded as D1. The package is now slid over the surface 101 and towards straight end edge 103 such that the center of gravity of the package rests over the straight end edge 103 and such that only half of the surface S1 of the package is now supported by surface 101. Ceiling surface 104 must be large enough to completely cover, at a minimum, the portion of the package that remains on surface 101, and exerts a weight approximately equivalent to that of the package being measured, or within 10% of the weight of the package, to prevent the package being measured from pivoting around the straight end edge 103 and falling from surface 101 prematurely. At this point the portion of the package that is not supported by surface S1 may be inclined as per the force of gravity to bend 5 over the straight end edge 103 towards floor surface 102. The maximum vertical distance, V (106), that the package reaches from a horizontal plane including surface 101 towards floor surface 102 is recorded as V1. If the package does not get to cross the horizontal plane that includes surface 101, then V1 is equal to 0. The drape measure, DM, is now calculated as V1 divided by D1, so DM=V1/D1. All dimensions are measured with the same unit of length, such 10 that the DM ratio is adimensional (or dimensionless). The drape measure is reported as an average of 3 measurements.

Example 1

The following table shows drape measurements taken for three bags of various weights, and for two different kinds of bundles, showing how the bundles have a much lower drape 15 measure as compared to individual bags. This is indicative of a stiffer package prepared only with laminate materials.

Actual Weight Length Width D 1 V 1 Sample Description (LB) (IN) (IN) (IN) (IN) DM 15 lb-Side Lay Flat Large Bag 15.2 21.77 12.84 3.3 4.4375 1.3447 Gusseted Bag 26 lb-Side Lay Flat Large Bag 26.45 25.75 16.627 4.264 4.5625 1.0700 Gusseted Bag 33 lb Side Lay Flat Large Bag 33.3 23.848 19.018 4.0875 6.5625 1.6055 Gusseted Bag 3-10.5 lb Bag Lay Flat Large Bags 32.35 19.1 14.35 8.05 1.0625 0.1320 Bundle in bundle 3-12 lb Bag Stand Up Bags in 36.3 18.169 10.049 9.845 1.4725 0.1496 Bundle bundle

Example 2

A focus group of shoppers who frequently purchase 50-pound, pliable bags of dog food are shown four packaging configurations. The first is a package as described above, with 3 bags each containing about 16.6 pounds of dog food and secured to each other via a substantially continuous overwrap with discontinuities at two ends of the package. The second configuration is a rigid cardboard container shaped like a cube, with partial oval cut-outs in two sides of the cube that serve as handles. The third configuration is a roughly cube-shaped bag, sometimes called a Smart Cube. The fourth configuration is a conventional 50-pound bag of dog food. The focus group was given the opportunity to view, touch, and handle each package, as each group member desires. The focus group indicated that the package as described above appears to be easier to store and better for protecting the freshness of the food after the bag or package it opened. The focus group further indicated that the package as described above is easier to lift and manipulate than the other packages.

Example 3

Electromyography was used to measure muscle activation in adult human volunteers lifting comparable weights of dog food in different package configurations. Electromyography (EMG) is a technique of measuring muscle activation by recording the electrical potentials that cause muscle fiber contraction. Specifically, EMG measures the electrical signals that are sent by the brain through the nerve to the motor units in the muscles. The motor units use the electrical signal to contract muscle fibers which are spread throughout the muscle. The more motor units stimulated, the more muscle fibers contract, creating a stronger contraction. Muscle activation results can be used to compare the effort required to lift a load, as well as which muscle group(s) are activated. High muscle forces in the hands and arms can cause pain and fatigue.

EMG was measured by placing two electrodes on the skin above the muscle of interest about 1-2 cm apart from one another. Female subjects were selected from a pool of volunteers aged 18-95 who purchase single pack pet foods of approximately 35 pounds. Volunteers were excluded from the study for medical conditions which contraindicated lifting 35 pounds or EMG (e.g., allergies to latex, adhesives, or gels used in the test, use of a pacemaker or hearing aid, open wounds in areas where EMG sensors would be placed, recent acute injury, or recent surgery). Measurements were taken to calibrate Maximum Voluntary Contraction (MVC). Results were reported in % MVC for each volunteer, to account for differences in muscle structure and strength between individuals.

Each volunteer was asked to handle, in randomized order, a bundle pack of dry dog food as shown in FIG. 3, weighing a total of 35 pounds, a large single pack of commercially available dry dog food weighing 33 pounds, and a cardboard box of dry dog food weighing 33 pounds. For each handling exercise, the volunteer was asked to lift the package from a 5-inch pallet (to simulate lifting the package from an endcap display or low shelf), transfer the package to a shopping cart, remove the package from the shopping cart, and place the package on a meeting room table (to simulate placing the package in an automobile trunk). The order of handling the different packages was randomized—some subjects lifted the box first, some subjects lifted the bundle pack first, and some subjects lifted the individual bag first. Percent MVC was measured for each activity by each volunteer at the shoulder (Medial Deltoid), upper arm (Biceps Brachii and Triceps Brachii), and forearm (Flexor Carpi Ulnaris). The results are shown in FIG. 6 (handling the packages relative to a shopping cart) and FIG. 7 (handling the packages relative to a pallet). FIGS. 6 and 7 show that the percent MVC for the bundle pack was comparable to or better than the single pack and box even though it was slightly heavier. In addition, qualitative ergonomic observations included less back bending when lifting the bundle pack compared to the alternatives (which explains why the arm muscle activation was slightly higher in some circumstances). Also, volunteers of shorter stature had to lift the single pack and box above their chest to place those packages into and lift those packages from a shopping cart, but did not have to do so with the bundle pack.

Handling the bundle pack by openings 40 provided further benefits in terms of reducing stress on the back. Examples of handling the bundle pack by openings 40 are shown in FIG. 8. Examples of handling the bundle pack other than by openings 40 are shown in FIG. 9. Average percent MVC for various muscle groups when handling the bundle pack by openings 40 or in another manner are shown in FIG. 10. Handling the bundle pack by openings 40 increases the use of the triceps and decreases the use of the biceps and forearm, which is ergonomically preferred.

The dimensions and values disclosed herein are not to be understood as being strictly limited to the exact numerical values recited. Instead, unless otherwise specified, each such dimension is intended to mean both the recited value and a functionally equivalent range surrounding that value. For example, a dimension disclosed as “40 mm” is intended to mean “about 40 mm.”

Every document cited herein, including any cross referenced or related patent or application, is hereby incorporated herein by reference in its entirety unless expressly excluded or otherwise limited. The citation of any document is not an admission that it is prior art with respect to any invention disclosed or claimed herein or that it alone, or in any combination with any other reference or references, teaches, suggests or discloses any such invention. Further, to the extent that any meaning or definition of a term in this document conflicts with any meaning or definition of the same term in a document incorporated by reference, the meaning or definition assigned to that term in this document shall govern.

While particular embodiments of the present invention have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this invention. 

What is claimed is:
 1. A package comprising: a first pliable bag containing a first flowable solid and a headspace; and a second pliable bag containing a second flowable solid and a headspace; wherein the first pliable bag and the second pliable bag are bound together to reduce an effective headspace in the package while the bags are bound.
 2. The package of claim 1, wherein the first pliable bag and the second pliable bag are stacked such that one side of the first pliable bag faces a corresponding side of the second pliable bag, and the opposing sides of the first pliable bag and the second pliable bag are substantially covered by an overwrap.
 3. The package of claim 2, wherein the overwrap comprises shrink wrap.
 4. The package of claim 2, wherein the overwrap comprises stretch film.
 5. The package of claim 2, wherein the overwrap reduces an effective headspace in the first pliable bag by at least 75%.
 6. The package of claim 2, wherein the overwrap reduces the effective headspace in the first pliable bag and an effective headspace in the second pliable bag, each by at least 75%.
 7. The package of claim 2, wherein the overwrap is continuous.
 8. The package of claim 2, wherein the overwrap is transparent.
 9. The package of claim 2, wherein the overwrap is opaque.
 10. The package of claim 2, wherein the overwrap comprises an easy-open feature.
 11. The package of claim 1, wherein the first pliable bag and the second pliable bag are folded to reduce the effective headspace in the bags before they are bound.
 12. The package of claim 11, wherein the first pliable bag and the second pliable bag are folded over at a top or a bottom.
 13. The package of claim 11, wherein the first pliable bag and the second pliable bag are folded at gussets, creases, darts, or other constructed fold lines to reduce an effective headspace of the bag.
 14. The package of claim 1, wherein the first pliable bag and the second pliable bag each contain between 8 and 50 pounds of a flowable solid.
 15. A package comprising: a pliable bag containing at least 10 pounds of a flowable solid; a headspace comprising at least 20% of a volume of the pliable bag; wherein the pliable bag is folded to reduce the effective headspace of the bag and the fold is frangibly secured.
 16. The package of claim 15, wherein the pliable bag has a fold, and the fold is secured by a securement selected from the group consisting of tape, adhesive, overwrap, mesh, mechanical-fit, or combinations thereof.
 17. A method of making a heavy package of flowable solids easier to handle, comprising: providing a pliable bag containing between 40 and 120 pounds of a flowable solid; reducing an effective headspace of the pliable bag by folding or compressing the pliable bag; and frangibly securing the pliable bag in the folded or compressed condition.
 18. The method of claim 17, wherein the effective headspace of the pliable bag, after reduction, is less than 5% of a volume of the pliable bag.
 19. The method of claim 17, wherein the pliable bag is frangibly secured in the folded or compressed condition by a securement selected from the group consisting of tape, adhesive, overwrap, mesh, mechanical-fit, or combinations thereof. 